Summaries

of FY 1980

Engineering Research

U.S. Department of Energy

Office of Energy Research

Office of Basic Energy Sciences

Division of Engineering, Mathematical & Geosciences

March 1981
Summaries

of FY 1980

Engineering Research

U.S. Department of Energy

Office of Energy Research

Office of Basic Energy Sciences

Division of Engineering, Mathematical & Geosciences

March 1981
FOREWORD

This report documents the basic Engineering Research program of the

DOE Office of Energy Research. Dr. Oscar P. Manley is the Engineering

Research program manager. This program is administered by the Division

of Engineering, Mathematical and Geosciences in the Office of Basic Energy

Sciences which is a major organizational unit of the Office of Energy Research

(OER). The fiscal year 1980 operating funds managed under this program

amounted to $2.3 million. Of the thirty-two projects constituting the

program in 1980, eight were underway at DOE laboratories, fifteen at universities, seven at private sector laboratories, and two at other government

agencies.

This report responds to a perceived need for this kind of compilation

by university and other scientists, by congressional staff, and by staff

of other executive departments when they are concerned with implementation

and coordination of energy and other research projects and programs.

The OER basic Engineering Research program addresses engineering areas

perceived as essential for progress in many energy technologies. Emphasis

and high priority are accorded to projects and proposals with the objective

of providing fundamental data and understanding for longer-range advances

in energy processes and systems. The program complements the necessarily

shorter-range focus of engineering reseach carried on in conjunction with

DOE technology programs.

Currently identified, high priority, basic engineering research areas

are: tribololgy, heat transfer, process control, instrumentation for

hostile environments, elastoplastic deformations, engineering aspects

of combustion, and resource recovery. Notable among projects underway

in 1980 were projects dealing with: surface-fluid interactions in support

of research in tribology and percolation, non-imaging optics for design

of more efficient solar collectors, high temperature electronics for control

systems in hostile environments, methods for solid-solid and solid-liquid

separation for resource recovery, modeling of elastoplastic deformation and

crack propagation in engineering structures, automatic on-line process

analysis, automation of non-destructive testing of materials, combustion of

lean fuel-air mixtures, heat exchange, and systems vibration and wear.

This is the first report of this type prepared for this program. To

expedite publication, the approach taken was to have staff adapt summaries

from project documentation submitted prior to and early-on in the fiscal

year. The principal investigators have not been given the opportunity

to review or approve the summaries as published. It has not been the

intent to convey significant scientific results of the projects, but rather

to indicate the area and scope of the research. For more detailed information

about a given project, it is suggested that the investigators be contacted

directly.

James S. Coleman, Director

Division of Engineering,

Mathematical and Geosciences

Office of Basic Energy Sciences

iii
INTRODUCTION

The purpose of the report is to provide a convenient compilation of

summaries of the individual research project (tasks) that constitute the

OER basic Engineering Research program for fiscal year 1980.

The report is ordered alphabetically by institution with all of the

project entries for an institution following the institutional-departmental

heading. In a monotonically increasing sequence, each project entry begins

with an underlined identification number. This is followed, reading across

the page, by the project title, the funding level, and a coded sequence, e.g.,

80-2. The first two digits of this sequence indicate the fiscal year in which

the project was authorized; the digit following the hyphen indicates the

anticipated duration of the project in years. If the anticipated term of the

project is indefinite, the capital letter I follows the hyphen instead of a

digit. If the funding period is other than twelve months, the number of

months in the funding period appears immediately below the funding level. A

funding level is paranthesized to indicate that it is a prior year obligation

and that there was no obligation for support of the project in fiscal year

1980. The names of the investigators are given immediately below the project

title; at the DOE laboratories, the first name listed is that of the designated

"task manager". The summary description of the project completes the project

entry. The indexes both refer to the project numbers rather than to page

numbers.

The participating DOE laboratories in fiscal year 1980 were:

Argonne National Laboratory (ANL)

Idaho National Engineering Laboratory (INEL)

Lawrence Berkeley Laboratory (LBL)

Lawrence Livermore National Laboratory (LLNL)

Los Alamos National Scientific Laboratory (LANSL)

Oak Ridge National Laboratory (ORNL)

Pacific Northwest Laboratory (PNL)

Sandia National Laboratories, Albuquerque (SNL-A)

iv
TABLE OF CONTENTS

Page

Argonne National Laboratory .................................. o 1

Battelle Columbus Laboratories o...................... ...... .. 2

Biphase Energy Systems ..........0...00 0000................. ..3

Calspan Corporation ........................................... . 4

Carnegie-Mellon University...OOO 0000.... . o................... 4

Carpenter Environmental Associates, Inc.........................o 5

University of Chicago o.......o0000................... .......... 6

Colorado School of Mines... ............. o .... o ....... o...... 7

Idaho National Engineering Laboratory 0.....0 ....... 00 ...o....... 7

University of Illinois at Urbana-Champaign.......o............... 8

Illinois Institute of Technologyo . 000.0O .... o 0O. ..... . ..... ..... 9

University of Iowa ................ ...... ooo.. i11 oo... 

Lawrence Berkeley Laboratory ........o.......................... 12

Lawrence Livermore National Laboratory ........................... 12

Los Alamos National Scientific Laboratory ....................... 13

Massachusetts Institute of Technology .. O.....o.................0 13

University of Michigan.................... ....................... 16

National Academy of Sciences ooo........................0000.... 17

National Bureau of Standards ....... oo... ........................ 18

City University of New York ..... o......... ......... ...... ... 18

Polytechnic Institute of New York .. o.............o........... oo. 19

Oak Ridge National Laboratory ............. o.... o............ . . 19

Pacific Northwest Laboratory ...................................o 20

Pennsylvania State University 0 0 0 ................ 00.....o o .... o . 20

Sandia National Laboratories, Albuquerque........................ 21

Scientific Systems, Inc ....000.............00..000O OOOO ... O....O 22

SKF Industries, Inc ................. O... ..................... .. 22

Southwest Research Institute ..................... .............. 23

University of Wisconsin ..... ..................... oo......... .. 23

Project Title Index.............................................. 24

Investigator Index ............................... ............... 26

V
ARGONNE NATIONAL LABORATORY

Components Technology Division

9700 South Cass Avenue

Argonne, Illinois 60439

1. ENGINEERING MODELS IN $ 45,000 80-2

DYNAMIC PLASTICITY

G. S. Rosenberg, R. A. Valentin

The general objective is to develop a rational continuum basis for describing the dynamic plastic deformation of metals subjected to short duration,

high intensity loading. A phenomenological rather than microscopic approach guides the derivation of constitutive representations, while classical

irreversible thermodynamics provides rationale for specific representations.

To bridge the gap between theory and eventual engineering application,

consideration is given to development of analytical methods which define

upper bounds on deformation history in terms of easily measurable load and

Omaterial parameters. To maximize the eventual utility of theoretical

models, the relationship between derived constitutive representations and

available conventional materials data is explored. Particular emphasis

is placed on representing multidimensional effects in terms of uniaxial

test data.
2

BATTELLE COLUMBUS LABORATORIES

Structures and Mechanics Research

Department

505 King Avenue

Columbus, Ohio 43201

2. DAMAGE ACCUMULATION BY CRACK $ 42,000 80-2

GROWTH UNDER COIBINED CREEP

AND FATIGUE

Carl E. Jaske

This project was authorized to begin in September of 1980. The proposed

research is made up of simultaneous experimental and analytical tasks.

These will be interactive; the results of one will provide direct feedback to the other throughout the course of the program. Analytical work

will be directed toward evaluating the sensitivity of the basic approach

to important independent variables, establishing critical conditions for

experimental work, and refining and/or modifying the methodology as required. Type 316 stainless steel will be used for the experimental studies

because it is commonly employed in many high-temperature applications in

the energy industry and because its mechanical properties have been well

characterized in past experimental programs, eliminating the need for

extensive background materials data development in the present study.

Baseline crack growth data will be developed in terms of da/dt versus

C* for creep and da/dN versus AJ for fatigue. Hold-time, creep-fatigue

tests will be conducted on precracked specimens. Selected test conditions

will be based upon analytical predictions of the approach. Both center-cracked and compact-tension geometries will be employed. Results of these experiments will establish confidence in the analytical approach that eventually

evolves.
3

BIPHASE ENERGY SYSTEMS

2800 Airport Boulevard

Santa Monica, California 90405

3. TWO PHASE FLOW RESEARCH $ 59,000 80-3

W. Amend, L. Hays

This project was authorized to begin in June of 1980. It is planned as

a three year effort to carry out research on two-phase flow nozzles and

their mass/momentum exchange interaction with the liquid phase film on

a rotating separator. During the first year, the investigators will experimentally evaluate the analytically computed optimum nozzle length for a

given scale of atomized particle. In addition, the optimum trade-off

between atomization pressure drop (resulting in various particle sizes)

and nozzle presure drop will be established for a constant overall energy

inputo The work will be carried out utilizing air and water at ambient

temperature with a nominal mass ratio of 10:1. Experimental data will

be obtained using the Biphase nozzle thrust/reaction table, which utilizes

calibrated strain gage load cells to measure nozzle performance. In the

second year work will go forward to determine experimentally the momentum

exchange efficiency between a high energy two-phase jet flow and the liquid

film formed on the inner surface of a rotating separator. Of particular

importance are the effects of liquid film thickness and velocity relative

to the impinging jet. The effect of nozzle jet impingement angle will

also be quantified. Separator film thicknesses will be varied from 0.0 to

0.75 inch, whereas, the relative velocities will vary from 0 to 200 fgs.

The angle of incidence of the jet to the film will vary from 5 to 30

Both the nozzle thrust table and the rotating separator will be used to

measure the momentum transfer efficiency under the various operating conditions. The final year of the research will quantify the wave-making interactions between external disturbances and a rotating separator liquid film.

Study of the effect of two-phase nozzle jet perturbation to the film will be

carried out over a range of Reynolds numbers, Froude numbers, and relative

scales of the disturbance to the film depth, in order to establish the the

relevant wave making characteristics. All tests will be documented photographically to record the various wave heights and angles. The effect

of Coriolis forces will also be quantified through consistent variation

in the Rossby number.
4

CALSPAN CORPORATION

Advanced Technology Center

Environmental Systems Department

P. 0. Box 400

Buffalo, New York 14225

4. MITIGATION OF BIOFOULING $ 65,000 80-3

USING SURFACE COATINGS

Dennis W. Goupil

This project was authorized to begin in September of 1980. It is concerned with the testing, development and application of improved nontoxic

antifouling coatings for use in heat exchange condensers. A preliminary

series of experiments is proposed to determine if the relationship between

surface chemistry and biological adhesion that has been developed from

studies of the fouling environment of the blood, the mouth, and the sea can

be applied to the biofouling problems in power plants. The three year

program will progress gradually from the testing of coatings subjected to

water from laboratory aquaria (1st year) to field studies performed with

saltwater (2nd year) and freshwater (3rd year). At the conclusion of the

program, it is anticipated that the basic engineering research involved in

the application of coatings to heat exchangers in both saltwater and freshwater will be completed.

CARNEGIE-MELLON UNIVERSITY

Department of Mechanical Engineering

Schenley Park

Pittsburgh, Pennsylvania 15213

5. MODELING OF SPRAY COMBUSTION ($110,000) 79-2

William A. Sirignano 24

Theoretical research is underway on the problem of spray combustion in

a multi-dimensional, unsteady, turbulent, two-phase flow. The liquid

is a multicomponent fuel with heavy hydrocarbon components such as found

in the alternative coal-derived and shale-derived liquids. Therefore,

in order to accurately predict vaporization rates and gas-phase mixture

ratios, a large system of equations is required. The equations governing

the gas enthalpy, gas velocity, and gas turbulent scales are parabolic.

The subsystem of equations governing the liquid-phase properties (droplet

velocity, droplet radius, droplet surface temperature, and droplet number

density) are hyperbolic, with some tendency towards a parabolic character

due to turbulent diffusion of the droplets. The research during the first

year has concentrated on the study of a model system of equations. Physically

meaningful multi-dimensional spray combustion cases will now be studied

utilizing results from the study of the model equations.
5

CARPENTER ENVIRONMENTAL ASSOCIATES, INC.

198 Walnut Street

Northvale, New Jersey 07647

6. PLASMA JET EXTRACTION OF $ 50,000 80-1

OIL SHALE

Ali Cambel

This project was authorized to begin in September of 1980. The investigators will undertake an exploratory proof of concept study to determine

whether or not plasma arc jets may be used to advantage in accelerating

shale oil production. The project plan specifies a four stage study

consisting of: 1) system design, 2) net energy analysis of the system

design, 3) an environmental evaluation of the system design, and 4) a

bench type laboratory experiment. In stage one, a systems study of how

plasma arc jets may be incorporated into shale oil recovery will be completed; two basic configurations will be considered, solo and hybrid

systems to augument existing schemes. Different configurations of arc

jets will be considered as well as the use of different gases as feed

stock. Systems diagrams will be made to predict yield per day. The entire

proposed technology will be described and configuration diagrams will be

presented. In stage two, a comparative net energy analysis will be performed. This will consist of two approaches: 1) a pure net energy analysis, and

2) a hybrid net energy analysis developed by Frantz and Cambel, consisting of

net energy analysis and input/output analysis. The net energy ratio for the

various configurations developed will be calculated. In the third stage, a

mini-environmental assessment of the system design will be performed particularly to establish if sulphur and nitrogen may be deleterious. In the last

stage, a laboratory bench experiment will be conducted to determine if hopes

and predictions for the system can be realized. In order to be able to make

a comparison, a modified Fischer assay will be conducted. This will consist

of a tank wherein a 100-gram sample of oil shale is heated. The variables

will be the time, the temperature and the yield. They will clearly be

different because the plasma temperatures will be considerably higher than

the 5000 C commonly used in a conventional Fischer assay. Use of a standard

procedure, the Fischer assay, will give a good indication of the effectiveness of plasma jets in oil retorting and will yield definitive comparisons.
6

UNIVERSITY OF CHICAGO

Enrico Fermi Institute

5630 Ellis Avenue

Chicago, Illinois 60637

7. FUNDAMENTALS AND TECHNIQUES $ 75,000 80-1

OF NONIMAGING OPTICS FOR

SOLAR ENERGY CONCENTRATION

Roland Winston, Joseph J. O'Gallagher

The objective of this project is to carry out research in broadly defined

areas to explore the potential of nonimaging optics for solar energy concentration. The development of a new formalism, based on the geometric

vector flux concept, and the resulting discovery of new concentrator designs have stimulated a continuing effort to provide a broader theoretical

base in this new discipline. The research activities break down into two

modes or phases, one essentially devoted to fundamental theoretical questions and one devoted to exploration of promising applications. The former

provides a foundation to support new concepts and the latter provides

motivation and direction to the theoretical effort. The work is organized

in accordance with these divisions. In the mode of fundamental theoretical

questions, the research areas are: 1).extension and development of the

new formalism for the geometrical vector flux in nonimaging optics, 2)

analysis of the properties of the evolution of the phase space distribution

for radiation as it transits various concentrator designs, and 3) the

conduct of additional optimization studies of existing CPC, and multi-stage

concentrator designs. In the mode of exploring promising applications,

the activities include: 1) continued measurements on a concentrator with

large reflector gaps appropriate to developing a practical scale concentrator

for use with an evacuated receiver, 2) carrying out selected surveys of the

characteristics and directional distribution of diffuse radiation and the

associated response to nonimaging concentrators using a variety of approaches,

and 3) construction and optical testing of selected optimized cavity designs.
7

COLORADO SCHOOL OF MINES

Department of Chemical and

Petroleum-Refining Engineering

Golden, Colorado 80401

8. AN IMPROVED INSTRUMENT FOR $ 45,000 79-2

THE MEASUREMENT OF THE

THERMAL CONDUCTIVITY OF

NONELECTROLYTE LIQUIDS

E. Dendy Sloan, Michael So Graboski

This is the second year of this two year project. The prime objective

was to design and build an innovative transient hot wire thermal conductivity apparatus to measure the thermal conductivity of organic liquids at

ambient conditions and at high temperatures and pressures. This objective has

been accomplished. A second objective is to test the apparatus by comparing

measured thermal conductivities of liquid toluene with the excellent data

presented by Mani (1971). Toluene has been proposed as a reference standard

substance for thermal conductivity measurements (Trump (L977). A third

objective is to measure the thermal conductivity of two different oils

obtained from coal liquefaction processes as a function of temperature and

pressure. Work to accomplish the latter two objectives is well underway and

progressing satisfactorily.

IDAHO NATIONAL ENGINEERING LABORATORY

Fuels and Materials Division

P. O. Box 1025

Idaho Falls, Idaho 83401

9. NDE SYSTEMS AND ANALYSIS $ 75,000 79-3

D. E. Keefer, Lo S. Beller

This program addresses the application of Synthetic Aperture Focusing

Techniques (SAFT) to realization of the full resolution and sensitivity

of ultrasonic techniques for imaging, inspection and process control.

The approach is through finite-element, perturbation theory methods.

The result is expected to be up to an order of magnitude improvement in

usefulness of the ultrasonic techniques for inspection, imaging and process

control purposes.
8

UNIVERSITY OF ILLINOIS AT URBANA-CHAMPAIGN

Department of Chemical Engineering

Urbana, Illinois 61801

10. CONDITIONS FOR DROPWISE CONDENSATION $ 46,900 80-3

ON ELECTROPLATED GOLD

Jo W. Westwater

Recently, certain noble metals, including gold, have been shown to promote

dropwise condensationo This research project is aimed at gaining a better

understanding of the mechanism underlying the enhanced dropwise condensation

of water on gold films. It is hoped that improved understanding of this

phenomenon can be translated into the utilization of baser metal surfaces

for this purpose. The research may well contribute to a great improvement

in the efficiency of boiling/condensation heat exchangers because dropwise.

condensation results in much higher heat transfer coefficients. Work is

underway using electroplating for deposition of the gold surface. The

deposition variables and their effects on promotion of dropwise condensation

are being characterized. Steam at atmospheric pressure is the test vapor;

and the condensing heat transfer coefficient is being measured on vertical

flat circular test surfaces. Also work is underway on the surface analysis

of the plated surfaces using electron microscopy and Auger electron spectroscopy. It is planned to extend the work to other methods of deposition

in addition to electroplating.
9

ILLINOIS INSTITUTE OF TECHNOLOGY

Department of Mechanics and Mechanical

and Aerospace Engineering

Chicago, Illinois 60616

110 STUDY OF THE INTERACTIONS $ 72,000 79-2

BETWEEN FRICTION, WEAR

AND SYSTEM RIGIDITY

So Kalpakjian, Vo Aronov,

Fo D'Souza

In this research project, the investigators have undertaken an interdisciplinary investigation to: 1) study the effect of vibrations on frictional

mechanisms, 2) develop models of vibratory structure including contact

stiffness, and 3) analyze self-excited vibrations caused by friction. The

objective is an intensive investigation of wear processes in terms of interactions among friction, vibration and wear. The study is being carried out

both experimentally and analytically0 The design and construction of a

versatile apparatus has been completed. This design has the capability of

controlling the applied load, rigidity and damping of the total frictional

system0 Preliminary experiments indicate that the system, as designed and

constructed, is appropriate for the study undertaken0 Having completed the

design and construction of the special apparatus and instrumentation, future

studies will involve extensive experimentation concerning friction, wear and

vibrations.
10

ILLINOIS INSTITUTE OF TECHNOLOGY

Department of Electrical Engineering

3300 South Federal Street

Chicago, Illinois 60616

12. METHOD OF VIBRATIONAL CONTROL $ 48,000 80-3

IN THE PROBLEM OF STABILIZATION

OF CHEMICAL REACTORS

Semyon M. Meerkov

The intent of this research project is to develop a method to increase

the stability area of complex nonlinear dynamic systems. The continuous

stirred tank chemical reactor is being studied as a specific example of

such a system. Work has begun to develop a nonclassical control technique, the vibrational control, which will convert unstable equilibrium

positions into stable ones by means of parameter oscillation. In this

first year, analysis of vibratile parameters in the reactor is underway;

current work is considering pressure and flow. Also analyses are underway to determine the magnitude of the oscillations and the admissibility

of frequencies from a practical technological point of view. As the analyses

progress, work will begin on the derivation of equations containing a vibration parameter. Then an analysis of the effect of vibrational control on the

reactor will be completed and an estimation made of the increase in the

stability area.
11

UNIVERSITY OF IOWA

Division of Energy Engineering

Iowa City, Iowa 52242

13. CONVECTIVE AND RADIATIVE $ 55,000 79-3

TRANSFER FOR TURBULENT

FLOW IN ENERGY SYSTEMS

Theodore F. Smith, Ching Jen Chen

The overall objective of this research is an examination of the interaction of convective and radiative heat transfer for turbulent flow of

a radiatively participating gas through circular ducts. Within this

objective, the specific aims are: 1) formulation of the conservation

equations for mass, momentum, and energy transport in a manner suitable

for the intended applications and for solution on a digital computer,

2) identification and development of appropriate models to describe turbulent

and radiative transport properties, 3) development of solution techniques

which are efficient, convenient, and accurate, 4) acquisition and analysis of

velocity, temperature, and heat flux results in order to identify the contribution and significance of the various transport mechanisms, and 5) development

of limiting cases and simplified models which would be suitable for engineering

design studies. Results derived from this work are expected to provide a

better understanding of the various energy transport mechanisms occurring in

energy systems and to yield mathematical methods for evaluation of gas

velocity and temperature profiles when convection and radiation are simultaneously considered. During 1980, separate turbulent and radiant energy models

and a solution scheme have been developed. Work is beginning on the testing

of each model and the numerical scheme for individual accuracy and capability

before combined models are executed.
12

LAWRENCE BERKELEY LABORATORY

Energy and Environment Division

University of California

Berkeley, California 94720

14. IGNITION STUDIES $110,000 79-3

Elton J. Cairns, A. K. Oppenheim,

F. C. Hurlbut

This research project is a part of the Lean Engine Combustion Program.

Its main objective is to acquire fundamental knowledge on the role of

radicals in ignition of gaseous hydrocarbon-air mixtures. On the

experimental side, studies will be made of effects of jets of radicals

on ignition by means of electric sparks and photochemical irradiation

as well as RF excitation. The theoretical studies carried out at the

same time will concentrate upon the thermochemical aspects of ignition

with particular attention attached to a specific treatment of the process

emphasizing the detrimental effects of losses.

LAWRENCE LIVERMORE NATIONAL LABORATORY

Electronics Engineering Division

P. O. Box 808

Livermore, California 94550

15. CHEMICAL PROCESS MODELS AND $130,000 79-3

CONTROL TECHNOLOGY

E. K. Miller, Jack Frazer

The object of this research is to develop improved design methods for use

in the chemical industry in order to increase productivity and efficiency

in the laboratory, pilot plant, and production facilities. A laboratory

bench-scale apparatus with a problem environment similar to that found

in a commercial pilot plant is used. The goals are to be able to rapidly

characterize complex chemical reactions, determine optimum operating conditions, and develop control algorithms for achieving optimality under

adverse conditions.
13

LOS ALAMOS NATIONAL SCIENTIFIC LABORATORY

Energy Division

Po 0. Box 1663

Los Alamos, New Mexico 87545

16. HEAT PIPE ENGINEERING $ 75,000 79-3

Co Ro Emigh, Fo Co Prenger

Heat pipes offer unique advantages for efficiently transferring heat.

This program extends and improves the existing description of heat transfer

phenomena in heat pipes in order to achieve an improved engineering design

code for heat pipes with liquid metal working fluids at temperatures ranging

from 700-1800Ko Substantial revision in heat pipe theory and reformulation

of heat pipe design codes is being applied to the development of vertically

oriented, gravity assisted heat pipes. Continued theoretical and experimental

work is being directed towards improved understanding of the flow transition

phenomena, turbulent flow in the heat pipe evaporator and the effect of

long adiabatic sections on heat pipe performance.

MASSACHUSETTS INSTITUTE OF TECHNOLOGY

The Energy Laboratory

77 Massachusetts Avenue

Cambridge, Massachusetts 02139

17o PISTON RING FRICTION AND $ 75,000 80-3

VEHICLE FUEL ECONOMY

David P. Hoult, Joe M. Rife

This research project was authorized to begin in September of 1980. The

project addresses the development of a physical model for piston ringlubricant system design. The experimental base will come from a series

of experiments to be conducted in a high speed photographic rig, a friction

engine, and from flow visualization modelso The expected result of this

study is a model that will describe the fluid mechanics of lubrication

and the motion of piston rings in sufficient detail to be used for design

and performance analysis.
14

MASSACHUSETTS INSTITUTE OF TECHNOLOGY

Center for Advanced Engineering Study

77 Massachusetts Avenue

Cambridge, Massachusetts 02139

18o FURTHER DEVELOPMENT OF THE $ 68,000 79=3

METHODS OF THERMOECONOMICS

Myron Tribus

This research project is concerned with the development of Thermoeconomics--a new discipline in which the principles of thermodynamics,

engineering economy, and optimization are applied to systems which convert

or use energyo Thermoeconomics is similar in philosophy to conventional

approaches to thermodynamic analysis. The system is divided into subsystems

upon which energy, entropy, material, and economic balances are madeo By

developing a system of "transfer prices" the details of a subsystem may be

analyzed, and trade-offs between capital investment and thermodynamic dissipation made in such a way as to insure an overall system improvement. The work

accomplished in the first year includes: 1) development of a formalized

procedure for thermoeconomic analysis, 2) the development of measures which

serve to identify the largest potential economic improvements in a system,

3) formulation of a method for developing transfer prices which permit

system decomposition, and 4) development of a method to use the resulting

prices for system improvement by optimization. In this second year, work

is underway to further refine the methods and illustrate how to apply

them to systems of practical interest°
15

MASSACHUSETTS INSTITUTE OF TECHNOLOGY

Laboratory for Manufacturing and

Productivity

77 Massachusetts Avenue

Cambridge, Massachusetts 02139

19. IMPROVEMENT OF RELIABILITY $105,000 79-3

OF WELDING BY IN-PROCESS

SENSING AND CONTROL

Koichi Masubuchi, Henry M. Paynter,

Frans Van Dyck

The objective of this research project is to improve the reliability of

welding by developing "smart" welding machines. A smart welding machine

will be equipped with sensors, artificial intelligence, and actuators for

reducing welding errors by one or two orders of magnitude. Welding with

a "smart" welding machine system, when it is developed, will result in

a total manufacturing cost equal to or less than actual current manufacturing costs. For obtaining such results the smart welding machine

will be integrated into a manufacturing system that prepares the edges,

welds, inspects and repairs. The design of an Integrated Pipe Welding

System and the construction of its critical components is the envisioned

follow-on development effort to be based on results obtained in this study.

The ultimate objective is the introduction of the integrated system into

industry. Work in the first year has concentrated on basic study and development of prototype systems with significant development of concepts and

equipment for in-situ sensors of the welding process and of models of the

welding process. Work in this area is continuing at an accelerated pace.
16

UNIVERSITY OF MICHIGAN

Department of Mechanical Engineering

and Applied Mechanics

550 East University

Ann Arbor, Michigan 48109

20. LOSS CHARACTERISTICS OF $ 54,000 80-2

CORD RUBBER COMPOSITES

S. K. Clark, Farhad Tabaddor*

This is a joint research effort undertaken by investigators associated

with the University of Michigan and the B. F. Goodrich Tire Company. The

objective is to increase the understanding of the way in which internal

losses in a cord-rubber composite depend on the loss characteristics of

the constituents used to fabricate it, and by such understanding to make

available to designers in the rubber industry knowledge which will enable

them to assess such effects and to minimize them, where possible, within

constraints imposed by other design requirements. The research plan calls

for theoretical and computational studies and an associated experimental

program. The theoretical studies will consider methods and techniques

for calculating the loss characteristics of cord-rubber composites. The

experimental program is designed to clarify the role of constituent materials

in cord-rubber composite loss characteristics. Specifically, it will provide

a means of evaluating different levels of analytical treatment and should

also furnish valuable experimental data to the rubber industry for use

by designers where applicable.

*B. F. Goodrich Tire Company
17

NATIONAL ACADEMY OF SCIENCES

NRC Assembly of Mathematical and

Physical Sciences

Numerical Data Advisory Board

2101 Constitution Avenue

Washington, D.Co 20418

21. SUPPORT OF STUDIES AND $ 15,000 80-I

ACTIVITIES RELATED TO

EVALUATION AND COMPILATION

OF NUMERICAL DATA

Gesina Co Carter

The Department of Energy has joined with other federal government departments and agencies to support studies and other activities related to

evaluation and compilation of numerical data which are carried on by the

Numerical Data Advisory Board of the National Academy of Scienceso The

Numerical Data Advisory Board has acquired responsibilities related to

numerical data for the scientific and technical disciplines, for space

and time dependent data, and for interdisciplinary and socio-technical

areas, such as energy and environment° The Board functions to promote

private initiative in data compilation, evaluation, and dissemination,

and to enhance coordination between existing data programs.
18

NATIONAL BUREAU OF STANDARDS

Office of Standard Reference Data

Washington, D.C. 20234

22. SUPPORT OF CRITICAL $200,000 80-I

DATA COMPILATIONS

David R. Lide

The Office of Standard Reference Data of the National Bureau of Standards

is administering a collaborative program for preparation of compilations

of reference data for use by the science and engineering community. Proposals are being solicited from colleges and universities as well as from

non-academic organizations, both non-profit and commercial. Support may

be provided for salaries, computer costs, travel, and other services

necessary to carry out the work proposed. In addition, the Office of

Standard Reference Data provides technical assistance to projects funded

under this program. Each project supported is expected to lead to a publishable data compilation containing recommended values and accuracy limits.

Guidance for projects supported under this program requires integration with

other reference data activities coordinated by NBS under the authority of the

Standard Reference Data Act (Public Law 90-396) in order to meet standards of

reliability and assure compatibility with other related data.

CITY UNIVERSITY OF NEW YORK

Department of Chemical Engineering

The City College

Convent Avenue at 138th Street

New York, New York 10031

23. TOPICS OF INTERFACE MECHANICS $150,028 80-1

Benjamin Levich

This project was planned and proposed as an approach to a systematic investigation of the field of interface mechanics. In the first part of

the effort, the investigators reviewed a possible approach to the question of the influence of surface active substances (SAS) on the motion

of fluid-fluid interfaces. The necessity of applying separate analysis

to each hydrodynamical problem, involving SAS, was emphasized. In this

connection work went forward to investigate the influence of SAS on jets

breakup, on transport phenomena through liquid-liquid interfaces, and

on the motion of the interface when the Reynolds number is not small.

Also a reexamination of the problems involving particles near surfaces

was undertaken. In particular, the motion of particles near permeable

surfaces was studied. In the second part, attention was focused on the

unresolved problem of the motion of a three-phase boundary. This subject,

which is important for numerous engineering problems, was reviewed, and

effort was devoted to devloping a new approach to a solution of the problem of the moving contact line.
19

POLYTECHNIC INSTITUTE OF NEW YORK

Aerodynamics Laboratories

333 Jay Street

Brooklyn, New York 11201

24. ANALYSIS OF SHOCK IMPLOSION $ 41,000 79-2

Eli A. Mishkin

In this project, research has been undertaken to extend the hitherto developed

theory of a single strong imploding shock coming from infinity to: 1)

develop the analysis of an imploding shock wave in a pellet of finite dimensions, 2) extend the analysis to a succession of several shocks, 3) consider

cylinderical pellets, 4) consider the outside energies and the shape of the

impinging power pulses, and 5) if possible, consider non-homogeneous pellets.

Work has progressed in extension of the basic theory and in analysis of an

imploding shock wave in a pellet of finite dimensions. A technical report has

been published and another is being prepared for publication. The work has

now turned largely to the analysis of a sequence of several imploding shockso

OAK RIDGE NATIONAL LABORATORY

Chemical Technology Division

P. 0. Box X

Oak Ridge, Tennessee 37830

25. SEDIMENTATION AND SOLID-SOLIDS $ 75,000 80-3

SEPARATION

Jack S. Watson, Sam D. Clinton

The objective of this program is to examine, in a fundamental manner, solidsolid and solid-liquid separation techniques for energy related applications.

These applications include resource recovery from coal-conversion residues

and low grade ores, as well as effluent control from power plants. Specific

approaches to this problem include use of gravitational and magnetic forces,

search for innovative techniques for aiding sedimentation, and study of

effects of electric fields on particle aggregate.
20

PACIFIC NORTHWEST LABORATORY

Engineering and Physics Department

Battelle Boulevard

P. 0. Box 999

Richland, Washington 99352

26. NONDESTRUCTIVE ENGINEERING $ 75,000 79-3

EVALUATION

M. D. Erickson, T. P. Harrington,

P. G. Doctor

The purpose of this research task is to improve the performance of Nondestructive Evaluation (NDE) systems, reduce the labor intensity associated

with NDE inspection, and to develop a multidisciplinary approach to NDE.

The research methodology focuses on developing quantitative measurement with

available techniques of pattern recognition in computer science. Specific

models for NDE will be developed which are suitable for mini/micro computer

implementation. In addition, the skills of fracture mechanics and economic

analysis will be added to expand the capability of NDE to predesign analysis

of structures considering both engineering and economic factors.

PENNSYLVANIA STATE UNIVERSITY

Department of Mechanical Engineering

University Park, Pennsylvania 16802

27. THE OFFSET STRIP FIN - A GENERALIZED $ 46,000 79-2

UNDERSTANDING OF ITS PERFORMANCE

CHARACTERISTICS

Ralph L. Webb

This research project is concerned with the offset strip fin used in plate

fin heat exchangers. The objective is identification of optimized fin

geometries which will result in more efficient, lower energy consumption heat

exchangers. The research underway seeks to establish the friction characteristics of offset fin arrays using idealized surface geometries which span

geometric parameters of commercial interest. Work in design of the experimental apparatus has been completed and construction of the apparatus is

progressing. When experimental data become available, work is to begin

on a generalized correlation of the results which will permit the prediction

of optimum surface geometries. The anticipated results would enable manufacturers to establish performance improvement goals.
21

SANDIA NATIONAL LABORATORIES, ALBUQUERQUE

Condensed Matter and Device

Physics Research Department

P. 0. Box 5800

Albuquerque, New Mexico 87185

28. HIGH TEMPERATURE ELECTRONICS $ 50,000 80-3

G. A. Samara, R. J. Chaffin,

I. J. Fritz, R. A. Kiehl

High resolution pressure measurements are needed in oil, gas, and geothermal

acquisition. Quartz resonator pressure gauges based on the nonlinear elastic

properties of quartz fill this need. Their resolution could be significantly

enhanced at high temperatures if corrections can be made to account for

the temperature dependence of the third-order elastic constants. This task

focuses on characterizing this higher order effect in important engineering

materials (quartz and LiNbO3) from a practical and a fundamental viewpoint.

The task also includes formulation of a detailed theory to relate the observed

frequency shifts back to the fundamental third-order elastic constant and

their temperature dependences. Another critical electronic component presently

unavailable for high temperature electronics is the capacitor. The proposed

task includes materials research on the identification and understanding of

suitable, low conductivity, high dielectric constant materials (such as

Si N4, BN, Si02, and TiO ) at temperatures up to 500 C. The long-range

objective includes investigation of transistor and diode concepts suitable

for high temperature operation.
22

SCIENTIFIC SYSTEMS, INC.

Suite 309-310

186 Alewife Brook Parkway

Fresh Pond Shopping Center

Cambridge, Massachusetts 02138

29. ELECTRICAL COMPONENTS MODELING $ 74,500 80-2

TECHNIQUES FOR EFFICIENCY 24

AND STABILITY ANALYSIS

J. Baillieul, R. Washburn

The objective of this research project is to develop a theoretical framework for the design and control of pulse-width modulated and other energy

conversion systems, and to identify and analyze stability problems for

such systems. This project was authorized to start in September 1980. The

planned research is organized into four tasks: 1) development of a control

tthory of bilinear systems in which the controls are switches, 2) study of

n order pulse-width modulated linear systems, 3) study of distributed

parameter models and associated control techniques for thyristors and similar

high power electronic switches, and 4) study of the occurrence of chaotic

behavior in pulse-width modulated systems. Availability of the theoretical

framework which is the goal of this work would enable designers to develop

power supplies which operate nearer to their theoretical efficiency limits.

SKF INDUSTRIES, INC.

Technology Services Division

1100 First Avenue

King of Prussia, Pennsylvania 19406

30. LUBRICATION OF ENGINEERING $120,000 80-2

SURFACES - II

John I. McCool, Y. P. Chiu,

Stuart S. Gassel

This research project was authorized to begin in September of 1980. The

objective is to perform follow-on research on the characterization of

bearing surfaces for applications in the design of high performance traction

drives, gears, bearings, etc. Within the current state-of-the-art, feasible

and practical experimental and original analytic work is to be undertaken

within the following three areas: 1) evaluation of the key assumptions

regarding asperity deformation in contacting bodies; 2) assessment of the

statistical error in the bispectral moments of anisotropic rough surfaces

together with the compilation of additional reference values; and 3) experimental validation of the traction and film thickness predictions of TRIBOS,

a previously developed computer code, expansion of its capabilities, and

extension of the input data base.
23

SOUTHWEST RESEARCH INSTITUTE

Division of Engineering Sciences

6220 Culebra Road

San Antonio, Texas 78284

31. FEASIBILITY OF PHYSICAL SCALE $ 46,000 80-1

MODELS FOR DETERMINING

HYDRO-THERMO-MECHANICS OF HOT

DRY ROCK GEOTHERMAL ENERGY

EXTRACTION

Franklin T. Dodge

This project was authorized to start in September of 1980. The objective is to evaluate the use of scale models as a tool for studying hydrofractured hot dry rock reservoirs. The planned research calls for: 1) completion of a similitude analysis of all relevant processes, using full-scale data, mathematical models, and physical reasoning, 2) formulation of "scaling laws"--the required interrelations between model and full-scale physical properties and process variables, 3) evaluation of the feasibility of

satisfying the scaling laws--what materials are needed, how the fracturing

process and the fluid losses can be simulated, and so on, and 4) formulation of a rationale to interpret scale-model test results. If the feasibility

of scale models is demonstrated, more detailed studies, the construction

of models, and the comparison of model test data to full-scale data will

be proposed for later years' research.

UNIVERSITY OF WISCONSIN

Department of Chemical Engineering

1415 Johnson Drive

Madison, Wisconsin 53706

32. THE DEVELOPMENT OF PROCESS $ 77,000 80-3

DESIGN AND CONTROL STRATEGIES

FOR ENHANCED ENERGY EFFICIENCY

IN THE PROCESS INDUSTRIES

M. Morari, W. H. Ray, D. F. Rudd

This research project addresses the development of synthesis methods for

the design of efficient and resilient (i.e., flexible, operable, and controllable) heat exchanger networks for applications in process industries.

The design methods being developed include operability explicitly as one of

the objectives. The process industries are a major consumer of energy and

the improvement of energy efficiency is an important goal. The approach being taken involves two steps. The first is work to identify network

structure/ resiliency relationships. When these conditions are identified, it will be easy to judge the practicality of the synthesized structures and

to develop algorithms which synthesize practical structures. The second step is the development of a synthesis method for networks with good operability characteristics.
24

Project Title Index

Analysis of Shock Implosion ........................................ 24

An Improved Instrument for the Measurement of the

Thermal Conductivity of Nonelectrolyte Liquids .................. 8

Chemical Process Models and Control Technology ....................15

Conditions for Dropwise Condensation on Electroplated

Gold ....................................... ................... 10

Convective and Radiative Transfer for Turbulent Flow

in Energy Systems ............................................. 13

Damage Accumulation by Crack Growth under Combined

Creep and Fatigue .............................. .................. 2

Electrical Components Modeling Techniques for

Efficiency and Stability Analysis............... .................... 29

Engineering Models in Dynamic Plasticity........................... 1

Feasibility of Physical Scale Models for Determining

Hydro-Thermo-Mechanics of Hot Dry Rock Geothermal

Energy Extraction ................................................ 31

Fundamentals and Techniques of Nonimaging Optics

for Solar Energy Concentration...................... ............ 7

Further Development of the Methods of Thermoeconomics..............18

Heat Pipe Engineering ..... .. ............................................16

High Temperature Electronics ....................................... 28

Ignition Studies ................................................... 14

Improvement of Reliability of Welding by In-Process

Sensing and Control ............................................ i..19

Loss Characteristics of Cord Rubber Composites ..................... 20

Lubrication of Engineering Surfaces - II...........................30

Method of Vibrational Control in the Problem of

Stabilization of Chemical Reactors .............................. 12
25

Mitigation of Biofouling Using Surface Coatings.................... 4

Modeling of Spray Combustion ....................................... 5

NDE Systems and Analysis........................................... 9

Nondestructive Engineering Evaluation ................................ 26

Piston Ring Friction and Vehicle Fuel Economy ...................... 17

Plasma Jet Extraction of Shale Oil .................... ............ 6

Sedimentation and Solids-Solids Separation ....... .................. 25

Studies of the Interactions between Friction, Wear

and System Rigidity ............................................11

Support of Critical Data Compilations.... ... ..................... 22

Support of Studies and Activities Related to Evaluation

and Compilation of Numerical Data ................................ 21

The Development of Process Design and Control Strategies

for Enhanced Energy Efficiency in the Process Industries ......... 32

The Offset Strip Fin - A Generalized Understanding of

its Performance Characteristics ..................................27

Topics of Interface Mechanics .........9..... ....................... 23

Two Phase Flow Research.......................... .. .................. 3
26

Investigator Index

Amend, W. 3 Rife, Joe M. 17

Aronov, V. 11 Rosenberg, G. S. 1

Baillieul, J. 29 Rudd, D. F. 32

Beller, L. S. 9 Samara, G. A. 28

Cairns, Elton J. 14 Sirignano, William A. 5

Cambel, Ali 6 Sloan, E. Dendy 8

Carter, Gesina C. 21 Smith, Theodore F. 13

Chaffin, R. J. 28 Tabaddor, Farhad 20

Ching Jen Chen 13 Tribus, Myron 18

Chiu, Y. P. 30 Valentin, R. A. 1

Clark, S. K. 20 Van Dyck, Frans 19

Clinton, Sam D. 25 Washburn, R. 29

Doctor, P. G. 26 Watson, Jack S. 25

Dodge, Franklin T. 31 Webb, Ralph L. 27

D'Souza, F. 11 Westwater, J. W. 10

Emigh, C. R. 16 Winston, Roland 7

Erickson, M. D. 26

Frazer, Jack 15

Fritz, I. J. 28

Gassel, Stuart S. 30

Goupil, Dennis W. 4

Graboski, Michael S. 8

Harrington, T. P. 26

Hays, L. 3

Hoult, David P. 17

Hurlbut, F. C. 14

Jaske, Carl E. 2

Kalpakjian, S. 11

Keefer, D. E. 9

Kiehl, R. A. 28

Levich, Benjamin 23

Lide, David 22

Masubuchi, Koichi 19

McCool, John I. 30

Meerkov, Semyon M. 12

Miller, E. K. 15

Mishkin, Eli A. 24

Morari, M. 32

O'Gallagher, Joseph J. 7

Oppenheim, A. K. 14

Paynter, Henry M. 19

Prenger, F. C. 16

Ray, W. H. 32